Carlisle IntelliFlow RF2 Controls Owner's manual

CONTROLS MANUAL

EN

IntelliFlow™ RF2

Automatic and Manual Systems

For other languages of this service manual and

additional product information, please scan the

QR code above.

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EN

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CONTENTS

SAFETY 4-8

Safety Precautions .............................................................................................................................................. 7

Hazards/Safeguards ......................................................................................................................................... 5-8

EU CONFORMITY 9

EU Declaration of Conformity ............................................................................................................................... 9

INTRODUCTION 11-25

System Components-Automatic .......................................................................................................................... 11

Control Panel-Automatic .................................................................................................................................... 12

Fluid Components-Automatic ............................................................................................................................. 13

Theory of Operation-Automatic .......................................................................................................................... 14

System Configuration-Automatic ........................................................................................................................ 16

System Components-Manual .............................................................................................................................. 17

Control Panel-Manual ........................................................................................................................................ 18

Fluid Components-Manual .................................................................................................................................. 19

Theory of Operation-Manual .............................................................................................................................. 20

System Configuration-Manual ............................................................................................................................. 22

Product Introduction.......................................................................................................................................... 23

Complete System Part Numbering .................................................................................................................................. 27

Technical Specifications ..................................................................................................................................... 27

Process Configuration ........................................................................................................................................ 28

INSTALLATION 32-56

Electrical ........................................................................................................................................................... 32

Pneumatics ....................................................................................................................................................... 33

Paint Materials .................................................................................................................................................. 35

Air Cut-Off Kit (Manual Mode) ............................................................................................................................ 37

CCV Pulse Setup (Manual Mode) ........................................................................................................................ 42

External Air Connections .................................................................................................................................... 45

Auxiliary Signals ................................................................................................................................................ 46

Disposal Information ......................................................................................................................................... 52

RF2 Cloud Setup ............................................................................................................................................... 53

OPERATION 57-95

Powering Up the System .................................................................................................................................... 57

Navigation Bar .................................................................................................................................................. 52

Language Settings ............................................................................................................................................. 59

Running the System .......................................................................................................................................... 59

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CONTENTS

OPERATION (cont.)

Calibration ........................................................................................................................................................ 68

Manual Override/Local Fluid Control ................................................................................................................... 69

Shutting Down the System ................................................................................................................................ 71

Administrator Functions ..................................................................................................................................... 72

Setup ............................................................................................................................................................... 75

Back-Up/Restore ............................................................................................................................................... 92

Diagnostics ....................................................................................................................................................... 94

Data Log/Reporting ........................................................................................................................................... 96

Multi-Color Stack Light Functions ....................................................................................................................... 98

MAINTENANCE 100-123

Regular Maintenance Procedures and Recommendations ................................................................................... 100

Top Level Part Numbers .................................................................................................................................. 101

Component View and Spare Parts .................................................................................................................... 102

TROUBLESHOOTING 124-134

Alarm List ....................................................................................................................................................... 124

Troubleshooting-Festo VTEM Pressure regulator manifold .................................................................................. 128

Troubleshooting-Festo VTUG Solenoid Manifold ................................................................................................ 132

APPENDIX 135-205

Fieldbus I/O .................................................................................................................................................... 135

Schematics .................................................................................................................................................... 150

MANUAL CHANGE SUMMARY 206

WARRANTY POLICY 208

CONTENTS (cont.)

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SAFETY

SAFETY PRECAUTIONS

Before operating, maintaining or servicing any

Carlisle system, read and understand all of the

technical and safety literature for your Ransburg

products. This manual contains information that is

important for you to know and understand. This

information relates to USER SAFETY and

PREVENTING EQUIPMENT PROBLEMS.

To help you recognize this information, we use the

following symbols. Please pay particular attention to

these sections.

This manual lists standard specifications and service

procedures. Minor differences can occur between this

literature and your equipment. Differences in local or

municipal codes, manufacturer or plant requirements,

material delivery requirements, and more can make

variations unpreventable. Compare this manual to your

system installation drawings and other applicable

Ransburg equipment manuals to find these differences.

Careful study and continued use of this manual will

provide a better understanding of the equipment

functions and procedures. This will result in improved

operation, efficiency, and longer, trouble-free service

with faster and easier troubleshooting. If you need the

necessary manuals and safety literature for your

specific Ransburg system, contact your local Ransburg

representative or Ransburg directly.

A NOTE is information which is relevant to the

procedure in progress.

NOTE

! WARNING

The hazards shown on the following pages may

occur during the normal use of this equipment.

! CAUTION

A CAUTION! states information that tells how to

prevent damage to equipment or how to avoid a

situation that might cause minor injury.

! WARNING

A WARNING! states information to alert you to

a situation that might cause serious injury if

instructions are not followed.

! WARNING

The user MUST read and be familiar with the

Safety Section in this manual and the Ransburg

safety literature therein identified.

This equipment is intended to be used by trained

personnel ONLY.

This manual MUST be read and thoroughly

understood by ALL personnel who operate,

clean or maintain this equipment! Special care

should be taken to ensure that the WARNINGS

and safety requirements for operating and

servicing the equipment are followed. The user

should be aware of and adhere to ALL local

building and fire codes and ordinances as well as

NFPA-33 AND EN 50176 SAFETY

STANDARDS, LATEST EDITION, or applicable

country safety standards, prior to installing,

operating, and/or servicing this equipment.

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EN

AREA

Tells where hazards

may occur.

HAZARD

Tells what the hazard is.

SAFEGUARDS

Tells how to avoid the hazard.

Spray Area

Fire Hazard

Improper or inadequate

operation and

maintenance procedures

will cause a fire hazard.

Protection against

inadvertent arcing that is

capable of causing fire or

explosion is lost if any

safety interlocks are

disabled during operation.

Frequent Power Supply or

Controller shutdown

indicates a problem in the

system requiring

correction.

Fire extinguishing equipment must be present

in the spray area and tested periodically.

Spray areas must be kept clean to

prevent the accumulation of combustible

residues.

Smoking must never be allowed in the spray

area.

The high voltage supplied to the atomizer

must be turned off prior to cleaning, flushing

or maintenance.

Spray booth ventilation must be kept at the

rates required by NFPA-33, OSHA, country,

and local codes. In addition, ventilation must

be maintained during cleaning operations using

flammable or combustible solvents.

Electrostatic arcing must be prevented. Safe

sparking distance must be maintained between

the parts being coated and the applicator. A

distance of 1 inch for every 10KV of output

voltage is required at all times.

Test only in areas free of combustible material.

Testing may require high voltage to be on, but

only as instructed.

Non-factory replacement parts or

unauthorized equipment modifications may

cause fire or injury. If used, the key switch

bypass is intended for use only during setup

operations. Production should never be done

with safety interlocks disabled.

The paint process and equipment should be

set up and operated in accordance with

NFPA-33, NEC, OSHA, local, country, and

European Health and Safety Norms.

SAFETY

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AREA

Tells where hazards

may occur.

HAZARD

Tells what the hazard is.

SAFEGUARDS

Tells how to avoid the hazard.

Spray Area

Explosion Hazard

Improper or inadequate

operation and

maintenance procedures

will cause a

fire hazard.

Protection against

inadvertent arcing that is

capable of causing fire or

explosion is lost if any

safety interlocks are

disabled during operation.

Frequent Power Supply or

Controller shutdown

indicates a problem in the

system requiring

correction.

Electrostatic arcing must be prevented. Safe

sparking distance must be maintained between

the parts being coated and the applicator. A

distance of 1 inch for every 10KV of output

voltage is required at all times.

Unless specifically approved for use in

hazardous locations, all electrical equipment

must be located outside Class I or II, Division

1 or 2 hazardous areas, in accordance with

NFPA-33.

Test only in areas free of flammable or

combustible materials.

The current overload sensitivity (if equipped)

MUST be set as described in the corresponding

section of the equipment manual. Protection

against inadvertent arcing that is capable of

causing fire or explosion is lost if the current

overload sensitivity is not properly set.

Frequent power supply shutdown indicates a

problem in the system which requires

correction.

Before turning high voltage on, make sure no

objects are within the safe sparking distance.

Make sure that the control panel is interlocked

with the ventilation system and conveyor in

accordance with NFPA-33, EN 50176.

Have fire extinguishing equipment readily

available and tested periodically.

General Use and

Maintenance

Improper operation or

maintenance may

create a hazard.

Personnel must be

properly trained in the

use of this equipment.

Personnel must be given training in

accordance with the requirements of

NFPA-33, EN 60079-0.

Instructions and safety precautions must be read

and understood prior to using this equipment.

Comply with appropriate local, state, and

national codes governing ventilation, fire

protection, operation maintenance, and

housekeeping. Reference OSHA, NFPA-33, EN

Norms and your insurance company

requirements.

SAFETY

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EN

AREA

Tells where hazards

may occur.

HAZARD

Tells what the hazard is.

SAFEGUARDS

Tells how to avoid the hazard.

Electrical Discharge

There is a high voltage

device that can induce an

electrical charge on

ungrounded objects which

is capable of igniting

coating materials.

Inadequate grounding will

cause a spark hazard. A

spark can ignite many

coating materials and

cause a fire or explosion.

Parts being sprayed and operators in the

spray area must be properly grounded.

Parts being sprayed must be supported on

conveyors or hangers that are properly

grounded. The resistance between the part and

earth ground must not exceed 1 meg ohm.

(Refer to NFPA-33.)

Operators must be grounded. Rubber soled

insulating shoes should not be worn.

Grounding straps on wrists or legs may be

used to assure adequate ground contact.

Operators must not be wearing or

carrying any ungrounded metal objects.

When using an electrostatic handgun,

operators must assure contact with the handle

of the applicator via conductive gloves or gloves

with the palm section cut out.

NOTE: REFER TO NFPA-33 OR

SPECIFIC COUNTRY SAFETY CODES

REGARDING PROPER OPERATOR

GROUNDING.

All electrically conductive objects in the spray

area, with the exception of those objects

required by the process to be at high voltage,

must be grounded. Grounded conductive

flooring must be provided in the spray area.

Always turn off the power supply prior to

flushing, cleaning, or working on spray

system equipment.

Unless specifically approved for use in

hazardous locations, all electrical equipment

must be located outside Class I or II,

Division 1 or 2 hazardous areas, in

accordance with NFPA-33.

Avoid installing an applicator into a fluid

system where the solvent supply is

ungrounded.

Do not touch the applicator electrode

while it is energized.

SAFETY

Spray Area

High Voltage

Equipment

EN

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SAFETY

Electrical

Equipment

Electrical Discharge

High voltage equipment is

utilized in the process. Arcing

in the vicinity of flammable or

combustible materials may

occur. Personnel are exposed

to high voltage during

operation and maintenance.

Protection against

inadvertent arcing that may

cause a fire or explosion is

lost if safety circuits are

disabled during operation.

Frequent power supply

shutdown indicates a

problem in the system which

requires correction.

An electrical arc can ignite

coating materials and cause a

fire or explosion.

Unless specifically approved for use in

hazardous locations, the power supply, control

cabinet, and all other electrical equipment

must be located outside Class I or II, Division

1 and 2 hazardous areas in accordance with

NFPA-33 and EN 50176.

Turn the power supply OFF before working on

the equipment.

Test only in areas free of flammable or

combustible material.

Testing may require high voltage to be on, but

only as instructed.

Production should never be done with the

safety circuits disabled.

Before turning the high voltage on, make sure

no objects are within the sparking distance.

Toxic Substances

Chemical Hazard

Certain materials may be

harmful if inhaled, or if

there is contact with the

skin.

Follow the requirements of the Safety Data

Sheet supplied by coating material

manufacturer.

Adequate exhaust must be provided to keep the

air free of accumulations of toxic materials.

Use a mask or respirator whenever there is a

chance of inhaling sprayed materials. The mask

must be compatible with the material being

sprayed and its concentration. Equipment must

be as prescribed by an industrial hygienist or

safety expert, and be NIOSH approved.

Spray Area

Explosion Hazard —

Incompatible Materials

Halogenated hydrocarbon

solvents for example:

methylene chloride and 1,1,1,

- Trichloroethane are not

chemically compatible with the

aluminum that might be used

in many system components.

The chemical reaction

caused by these solvents

reacting with aluminum can

become violent and lead to an

equipment explosion.

Spray applicators require that aluminum inlet

fittings be replaced with stainless steel.

Aluminum is widely used in other spray

application equipment - such as material

pumps, regulators, triggering valves, etc.

Halogenated hydrocarbon solvents must never

be used with aluminum equipment during

spraying, flushing, or cleaning. Read the label

or data sheet for the material you intend to

spray. If in doubt as to whether or not a

coating or cleaning material is compatible,

contact your coating supplier. Any other type

of solvent may be used with aluminum

equipment.

AREA

Tells where hazards

may occur.

HAZARD

Tells what the hazard is.

SAFEGUARDS

Tells how to avoid the hazard.

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SAFETY

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INTRODUCTION—AUTOMATIC

The IntelliFlow RF2 (or RF2) is a standalone system designed to control material delivery from a supply

source (pressure pot or circulation system) to an applicator. It accurately controls material mixture ratio

and/or material flow in a coating process, which can include single component, 2k, or 3k materials, and

handles flushing and loading of the materials.

The RF2 can include up to four fluid channels (for additional details on Channels, refer to page 14 of this

manual) which can be arranged in many ways. The available channels can be configured into 1, 2, or 3

component mixes (guns), using any combination of these mixes to utilize all the available channels. The

RF2 can be configured to include anywhere from 32 to 128 solenoids, all of which are fully addressable to

be used in various ways to control the process (examples include applicator triggers, dump, solvent flush,

color-valve selects, etc.).

The channels and fluid mixes can be grouped into up to two stations with individual sets of color stacks,

which can be controlled completely independently of one another.

The RF2 can be operated locally, from its included 15-inch touch screen, or it can be easily integrated into

an automated process by use of discrete signals for simple systems or by multiple different industrial

fieldbus protocols for more advanced control.

The RF2 can be connected to the cloud, allowing access to Carlisle Fluid Technologies technical experts for

the purpose of remote troubleshooting. This access may also be granted to local plant personnel.

Data gathered by the RF2, including alarms and flow-totalization data is stored in an onboard SD card, and

can be accessed via FTP, or other methods.

SYSTEM COMPONENTS

1. Control panel

2. Valve stacks

3. Fluid control module

4. Mixing module

1

2

3

4

INTRODUCTION-AUTOMATIC

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CONTROL PANEL

External Components

1. Status light

2. Main power entry

3. Main power disconnect switch

4. Panel opening latch

5. Emergency stop button

6. HMI

Internal Components

1. Safety relay

2. Electronic circuit protector

3. Local ethernet switch

4. CPU/Controller

5. DC Power supply

6. Main power circuit breaker

7. Line filter

8. Connection to status light

9. Main power disconnect switch

connector

10. I/O block and additional terminals

11. Terminal blocks

12. Connection to HMI and emergency

stop button

1 2

3

4

5 6

1 2 3 4 5 6 7 8 9

12 11 10

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FLUID COMPONENTS

Valve Stack

1. Fluid pressure regulator (Optional)

2. Connection to fluid panel

3. Fluid valves

4. Connection to solenoids

5. Air push valve

6. Air regulator

7. Solvent flush valve

8. Check valve

Flow Control Module

1. Connection to valve stack

2. MVR (Material Valve Regulator) with air

gauge

3. Flow meter

4. Connection to control panel

5. Calibration block

6. Connection to mix module

Mix Manifold

1. Connection to gun

2. Static mix tube

3. Mix block

4. Solvent flush valve

5. Connections to flow control modules

1

2

3

4

5

6

8

7

1

2

3

4

5

6

1 2 3 4

5

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THEORY OF OPERATION

The RF2’s operating principle is as follows:

1. The material is fed through the hoses towards the material valves in each stack.

2. If multiple materials of the same type (Resin, Hardener, or Reducer) are being used, each valve will

control its flow separately.

3. The material valves are normally closed. When material flow is needed, the system controller opens the

valve via the solenoid addressed to it.

INTRODUCTION-AUTOMATIC

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4. The material flows from the valves to the flow control module.

5. The flow meter sends a signal to the control panel indicating the material’s current flow rate.

6. The control panel determines if the flow rate is within specification or not.

7. Through the MVR, the control panel increases or decreases the flow rate of material passing through,

to reach the desired value.

8. The material proceeds to the mix manifold where it combines with the second and/or third material.

9. The mixed material then flows to the gun’s inlet connection.

INTRODUCTION-AUTOMATIC

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RF2 AUTOMATIC SYSTEM CONFIGURATION

1. Air manifold

2. Valve stack solenoid manifold

3. Pressure solenoid manifold

4. Material A valve stack

5. Material B valve stack

6. Material A fluid panel

7. Material B fluid panel

8. Mix chamber

Air hosing

Solvent hosing

Material A lines

Material B lines

Mixed material lines

1

2

4

3

5

6 7

8

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INTRODUCTION—MANUAL

The IntelliFlow RF2 (or RF2) is a standalone system designed to control material delivery from a supply

source (pressure pot or circulation system) to an applicator. It accurately controls material mixture ratio

and/or material flow in a coating process, which can include single component, 2k, or 3k materials, and

handles flushing and loading of the materials.

The RF2 can include up to four fluid channels (for additional details on Channels, refer to page 20 of this

manual) which can be arranged in many ways. The available channels can be configured into 1, 2, or 3

component mixes (guns), using any combination of these mixes to utilize all the available channels. The RF2

can be configured to include anywhere from 32 to 128 solenoids, all of which are fully addressable to be

used in various ways to control the process (examples include applicator triggers, dump, solvent flush, color-

valve selects, etc.).

The channels and fluid mixes can be grouped into up to two stations with individual sets of color stacks,

which can be controlled completely independently of one another.

The RF2 can be operated locally, from its included 15-inch touch screen, or it can be easily integrated into

an automated process by use of discrete signals for simple systems, or by multiple different industrial

fieldbus protocols for more advanced control.

The RF2 can be connected to the cloud, allowing access to Carlisle Fluid Technologies technical experts for

the purpose of remote troubleshooting. This access may also be granted to local plant personnel.

Data gathered by the RF2, including alarms and flow-totalization data is stored in an onboard SD card, and

can be accessed via FTP, or other methods.

SYSTEM COMPONENTS

1. Control panel

2. Valve stacks

3. Fluid control module

4. Mixing module

1

2

3

4

INTRODUCTION-MANUAL

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CONTROL PANEL

External Components

1. Status light

2. Main power entry

3. Main power disconnect switch

4. Panel opening latch

5. Emergency stop button

6. HMI

Internal Components

1. Safety relay

2. Electronic circuit protector

3. Local ethernet switch

4. CPU/Controller

5. DC Power supply

6. Main power circuit breaker

7. Line filter

8. Connection to status light

9. Main power disconnect switch

connector

10. I/O block and additional terminals

11. Terminal blocks

12. Connection to HMI and emergency

stop button

1 2

3

4

5 6

1 2 3 4 5 6 7 8 9

12 11 10

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Valve Stack

1. Connection to fluid panel

2. Fluid valves

3. Connection to solenoids

4. Air push valve

5. Air regulator

6. Solvent flush valve

Pulse Valves

1. Connection to valve stack

2. Pulse valve

3. Flow meter

4. Connection to control panel

5. Calibration block

6. Connection to mix module

1

2

3

4

6

5

1

3

4

5

6

2

1

3

4

5

6

Component B & C

Component A

FLUID COMPONENTS

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THEORY OF OPERATION

The RF2’s operating principle is as follows:

In RF2 manual gun configurations with a pulse-valve channel type for the B and/or C components, fluid

from the hardener or reducer channels is “dosed” into the mixture in order to accurately control the

material ratio. The rate of pulsing and length of each pulse of fluid is regulated in order to achieve the

desired ratio.

For optimal performance, the pulse-valve will operate at 3Hz rate of fire, and all adjustments by the

controller will be through varying the length of each pulse. To achieve this, adjust the pulse-valve so the

flow through the valve when it is open is at 3Hz rate. Further instructions for adjusting the pulse-valve are

1. The material is fed through the hoses towards the material valves in each stack.

2. If multiple materials of the same type (Resin, Hardener, or Reducer) are used, each valve will control

its flow separately.

3. The material valves are normally closed. When material flow is needed, the system controller opens the

valve via the solenoid addressed to it.

INTRODUCTION-MANUAL

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Carlisle IntelliFlow RF2 Controls Owner's manual

Carlisle IntelliFlow RF2 Controls Owner's manual

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